3D Printing of Perfect Particles

way for a new production method for reproducible models of irregular powder beds.

deviation between experimental results and theoretical predictions observed, we paved the

artificial models to represent porous particle beds for liquid imbibition study. With some

considered. Thus, we 3D printed porous substrates building from simple to complex as

tortuosity in real-life powder beds or other industrial porous media usually are not fully

assumes a particle bed as an array of parallel capillaries. However, the complexity and

Wettability analysis for particulate materials has relied on the Washburn theory that

printed particles with complex geometry.

the first report of stress visualization and semi-quantification under low loads for 3D

material used in Polyjet printing was found to exhibit photoelastic properties. We presented

viable technique in understanding complex particle breakage behaviors. The Vero Clear

typically observed in Finite Element Simulations. Stress visualization also proves to be a

demonstrated the agglomerate strain distribution from the experiment in the same way

breakage from three dimensions using Digital Image Correlation (DIC). Preliminary results

In the fifth year, a more sophisticated approach was attempted to observe agglomerate

tuned by changing the liquid to powder saturation level.

Binder Jetting technique was used to produce agglomerates where the strength could be

over the agglomerate structure was plotted for the first time. In an additional study, the

tracking of individual particle position after agglomerate breakage. The strain distribution

properties. This was to provide feasible and accurate control on loading direction and better

process to produce 3D printed agglomerates with different color distributions and material

Building upon the initial findings, in the fourth year, colors were introduced in the printing

compressive load during the initial deformation of the agglomerate.

accurate predictions of the macroscopic breakage behavior and quantitatively predicted the

properties matching the 3D printed agglomerates. Qualitatively the DEM produced

simulated in EDEM using the Timoshenko Beam Bond Model (TBBM) with bond

tested under various standard breakage tests. Agglomerate deformation and breakage were

agglomerate design was systematically varied in terms of structure and bridge strength and

technique was used to print symmetrical or random agglomerate structures. The

the 3D printed structures and validating the results in the DEM simulations. The Polyjet

The first three years of the project investigated agglomerate breakage experimentally using

3. Agglomerate Flow and Segregation.

categories for a better understanding of agglomerate behavior:

printing techniques based on the properties required. The study was divided into three

Computer Aided Software’s (CAD) software’s, and printed using a wider range of 3D

overcome this barrier. Agglomerates were designed using various tools i.e. DEM and

new approach which involves 3D printing test agglomerates with “tunable” properties to

lack of suitable test particles that can be used to validate the models. This report presents a

One of the long term barriers to Discrete Element Modelling (DEM) of particulates is the